Catalyst regenerator and recovery apparatus



Feb 22, 1949, w. E. HULSBERG 2,452,193

CATAL'YST REGENERATOR AND RECOVERY APPARATUS Filed April 9, 1945 y f/zz eze for' www . Patented Feb. 22, 1949 UNITED STATES PATENT OFFICE CATALYST REGENERATOR AND RECOVERY APPARATUS William E. Hulsberg, Hinsdale, Ill.,.assignor to Universal Oil Products Company, Chicago, Ill., a corporation of Delaware Application April 9, 1945, Serial No. 587,251

6 Claims. l This invention relates to an improved apparatus for the regeneration and recovery of iluidized catalyst particles. The apparatus incorporates in a single unit a catalyst regenerator, a steam generating or heat recovery zone, and a ilue gas scrubbing zone for the recovery of catalyst particles. p

In the fluidized catalytic conversion of hydrocarbonsV the catalyst becomes contaminated in the reactor zone with a deleterious carbonaceous deposit. The fluidized conversion process is a continuous one, the deleterious deposit is burned from the catalyst particles in the regenerator and the particles then returned for reuse to the reactor where a continuous conversion process takes place. The fluidized catalytic cracking of hydrocarbons in particular, using a nely divided catalyst, is now well known to those familiar with the cracking art. It is advantageous to recover as much of the catalyst as possible following the regeneration of the particles so that they may be reused in the conversion process. The catalyst may be a natural clay or it may be a synthetically prepared nelydivided alumina-silica material, the nature of these various catalysts and their method of preparation are now known to those familiar with the art.

There are two principal methods of recovering catalyst iines subsequent to the regeneration of the catalyst particles and the initial cyclone sep- 57' aration step at the top of the regenerator. One method makes use of the Cottrell electrical precipitator, which is a rather expensive apparatus comprising a large chamber having a number of electrical elements therein. These elements are capable of ionizing the catalyst particles and precipitating them from the flue gas stream as it flows therethrough. A second method of recovering ne catalyst particles, subsequent to the regenerating step and the cyclone separating stage at the gas exit from the regenerator, entails the use of an oil scrubber. In the oil scrubber, catalyst rines are substantially all washed from the flue gases by a countercurrently owing gas-oil stream. In both of the above methods, a waste heat boiler is usually placed in the path of the nue gas at some point between the regenerator and the electrical precioitator or the scrubber. A steam generating boiler performs two functions. that of decreasing the temperature of the gas stream prior to its entry in1 the Cottrell or in the oil scrubber. ard that of recovering normally waste heat bv the generation of steam in the boiler or heat exchange type of apparatus. f

. 2 The improved apparatus of this invention combines within one unit or chamber, a regeneration zone, a steam generating zone and a flue gas scrubbing zone for the recovery of catalyst particles. The apparatus in its preferred form has an internal cylindrically shaped chamber for catalyst regeneration with the accompanying two zones housed in anular spaces surrounding this regenerating zone. A steam generating zone is in the inner annular space between an intermediate Wall and the regenerating chamber shell, while the ue gas scrubbing zone is in the outer annular space between the outer shell of the unit and the intermediate cylindrical wall.

Construction of the apparatus is such that the ue gas upon leaving the top of the regenerator iiows down around the regenerator wall into the inner annular space, over a plurality of vertically placed steam generating tubes distributed Within this annular space; much of the ue gas heat is thusA dissipated, being absorbed by the tube bank in the generation of steam. The intermediate cylindrical wall isnot as long as the inner and outer shells, so that the inner annular heatre'moving zone connects at the lower end with the outer annular scrubbing zone. Thus, the flow is upward through the contact bed in the said outer annular zone and the ilue gases are washed substantially free of catalyst particles before they are exhausted from the unit.

The liquid scrubbing medium, owing downward through the contact bed, forms -a catalyst slurry, which can drop into a reservoir, below the scrubhing zone, and from which the slurry may be gradually withdrawn. The washed ue gases are exhausted from the upper part of the outer lannular zone through a pressure controlling means into the ue gas stack. n

There are several advantages to this novel and improved apparatus. The insulated ue gas conduits or ducts which are normally required between the regenerator and waste heat boiler and between the waste heat boiler and the oil scrubber are unnecessary with the use of this invention. The expensive bellows type of expansion joints normally required, as well as the ue gas conduits, will also be eliminated. Separate scrubbing and waste heat boiler vunits with their independent supporting structures are no longer required with the use of this combined unit. while the supporting structure of the combined unit need be only slightly larger than that renuired bv the normal regenerating unit. With gas-oil ybeing used as Ia scrubbing medium the oil and catalyst slurry may be charged to the reactor together with the usual oil and regenerated catalyst charge. Since the regenerator level is normally positioned some distance above the inlet to the reactor, then the slurry may now by gravity from the reservoir to the reactor. The slurry pump, which is necessarily used with the separate scrubber column, thus becomes unnecessary when the scrubbing zone is combined in the regenerating unit. It should be noted that the construction of the combined unit is such that the internal regenerator chamber expansion is entirely independent "of the outer shells; also that the flow of the gas is such that the pressure on the interior of the regenerator is very little different from that in the zone surrounding the regenerator chamber shell, allowing the shell to be relatively light inweight.

The accompanying drawing shows an elevational view, partially in section, of the apparatus comprising this invention and the following description thereof should make the construction and advantages of the invention more apparent.

Referring now to the drawing, the inner shell I encloses the regeneration zone 2 wherein used catalyst particles having a carbonaceous deposit, are subjected to a burning operation while in a fluidized state of hindered settling. The used catalyst is carried to this regeneration zone 2 in a. uidized phase by way of conduit 3 and by means of an air or oxygen containing gas stream, from the outlet of the hydrocarbon reaction or conversion zone (not shown). The perforated grid plate 4 at the lower end of the regenerator, is used to distribute the incoming catalyst and gas stream. The regenerated catalyst is drawn oif through outlet 5, and is returned to the reaction zone for reuse. The combustion gases from the burning operation, or the flue gas, passes from the top of the regenerator through a cyclone separator 6 to the space between the regeneration zone 2 and the upperdome 'I of the apparatus. The separator 6 functions to remove as much of the entrained catalyst as pos-- sible. A plurality of "Multi-clone type of cyclone separating units 8 are indicated discharging into a common hopper with a single "dippipe 9; however, other separators such as the Buell type may well as used.

The flue gas with the major portion of the fine catalyst removed passes from the top of the regenerating unit down through the annular space or steam generating zone I which is between the regenerator shell I and the intermediate circular shell II. A plurality of vertical tubes I 2 are placed circumferentially around and extending into this zone I0, to form a steam generating bank which will absorb heat from the flue gas stream. Water enters the steam generating tubes I2 through the inlet conduit I3 and the lower circular header I4. The generated steam is drawn oif through the upper circular header I and the outlet conduit I6, being sent to a suitable steam collecting drum, which is not shown.

A high temperature insulating material II is shown attached to the wall I of the regenerating zone 2 and on the interior of the top dome 1 and the intermediate wall II. The type of insulating material I1 whether of insulating cement or a refractory, as well as the method of attachment, should of course be suitable for the temperature conditions to be encountered. The grid 4 and the shell I should also be made of alloy or metals suitable for the operation.

VA series of quenching nozzles I8` are provided at spaced points around and projecting into the upper part of the steam generating zone Ill. The nozzles I8 with the ow of the quenching liquid controlled by valves I8', are normally used only at periods when the flue gas temperature is excessive, as in the case of afterburning of the gases outside of the oxidation and regenerating zone 2, or atperiods to give aid in decreasing the flue gas temperature when the steam generating tube bank I2 is not functioning properly to effect the desired temperature drop.

The flow of the nue gas upon leaving the heat reducing zone I0 is downward, such that the flow must reverse direction and ow upward through the scrubbing zoneV and contact bed I9. The

contact bed I9 may be of Raschig rings or some similar packing medium, being supported on a perforated plate or grating 2D, in the annular space between the intermediate wall Il and the outer shell 2|' of the apparatus. Batlle plates or side to side decks mayt also be used in the contact zone ink lieuof a packing material lf it is so desired. The scrubbing medium which is to flow downward through the contact bed I9, countercurrent to the 'gas stream, may comprise a portion of the gas-oil charge to the recator in` connection with the fluid catalystcracking process, or it may be some other suitable iluid, for other processes. The scrubbing'operation will substantially free the iiue gas of any entrained catalyst particles, also the turn required by the ilow stream around the lower end oi wall II should cause some of the particles to be dropped out prior to the scrubbing operation. The gas-oil or washing liquid is sprayed onto the contact bed I9 through the perforated circular header 22. The gas-oil or liquid medium is charged to the header 22 through an inlet conduit 23, with the rate of iiow regulated -by a control valve 24. The control valve 24 is in turn regulated by the liquid level control apparatus `25 at the slurry reservoir 26.

The slurry of catalyst `and scrubbing oil, from the contact zone I9, falls to the bottom of the annular zone or reservoir space 26 which is formed by the bottomhead 21, the outershell 2l and the regenerator Wall I. When the insulating material I 'I is on the exterior of the shell I as shown, then an additional metal wall 28 is necessary for the slurry reservoir zone 26. The catalyst slurry may be drawn oif through a conduit 29 provided at the lower end of the annular reservoir.

'The waste flue gas after the scrubbing operation is discharged from the apparatus through one ormore pressure control valves 3i) or other suitable pressure reducing means, and through one or more iiue gas outlet stacks 3|.

It should be noted that the inner chamber wall I and the intermediate wall I I are not subjected to unequal pressure loadings and therefore may be of relativelyV light construction. Also, these same inner walls are free to expand without any expansionjoints or the like being required.

It is not intended to limit this invention or the apparatus to the particular construction details described or shown in the drawing. Many variations may be made to the apparatus and still come within the scope of this invention..`- For instance, modifications may bemadevas to size and shape; the type of cyclone separator; the type of contact bed in the .scrubbing zone; the type of insulation and the method of attachment to the walls; thextype-of grid distribution plate, etc.

I claim as my invention:

1. An apparatus of the class described comprising in combination an inner chamber, an outer chamber spaced from said inner chamber, means dividing the space between said chambers into two annular zones communicating at their lower ends, a cyclone separator in the upper portion of said inner chamber and communicating with the upper end of the inner one of said annular zones, cooling means in the `inner annular zone, contact means in the outer one of said annular zones, an inlet to the outer annular zone above said contact means, an outlet from the upper portion of the outer annular zone, and a reservoir between said inner and outer chambers below said annular zones.

2. An apparatus of the class described comprising an outer chamber, an inner chamber having side and top walls spaced from the side and top walls, respectively, of the outer chamber, said chambers having a common bottom wall, an opening in the top wall of the inner chamber and a cyclone separator positioned therein, an inter mediate vertical wall between and spaced from the side walls of said chambers and terminating above said Ibottom wall, heat exchange tubes in the space between said intermediate wall and the side wall of the inner chamber, contact means in the Space between said intermediate wall and the side wall of the outer chamber, an inlet to the last-named space above said contact means, and an outlet from the upper portion of said lastnamed space.

3. An apparatus of the class described comprising in combination an internal regenerating chamber, an external chamber around said internal chamber, an intermediate wall between and concentric with .both of said chambers forming thereby two annular zones, an inlet and an outlet connected to the lower end of said regenerating chamber, separating means positioned in the upper part of said internal regenerating chamber and communicating with the innermost annular zone, a heat exchanger positioned in said inner annular zone having inlet and outlet means, contact means in the outermost annular zone, an inlet and distributing means above said contact means in said outermost annular zone,

means connecting the lower part of said innermost annular zone and the lower part of said outermost annular zone, a reservoir below and common to 6 said annular zones, an outlet from said reservoir, and outlet means from the upper part of said outer annular zone.

4. An apparatus of the class described comprising in combination a vertically positioned cylindrical outer chamber, a concentric inner chamber, an intermediately positioned wall depending from the top of said outer chamber and forming thereby two annular zones between said inner and said outer chambers, an inlet at the lower end of said inner chamber, a perforated plate in the lower :portion of said inner chamber, a drawoif outlet from the interior of said inner chamber, a cyclone separator having an outlet at the upper end of said inner chamber, a flow space between the upper ends of said inner and said outer chambers connecting said outlet with the innermost zone of said two annular zones, a plurality of spaced apart vertically positioned heat exchange tubes in said inner annular zone, an inlet header to the lower end of each of said tubes, an outlet header to the upper end of each of said tubes, a contact bed in the outermost annular zone of said annular zones, an inlet and distributing header above said contact bed in said outermost zone, an outlet at the upper end of saidY outermost annular zone, a reservoir open to each of said annular zones and conned between said inner and outer cham-bers below said intermediate depending wall, and an outlet from the lower end of said reservoir.

5. The apparatus as described in claim 4 further characterized in that a plurality of spaced apart spray nozzles are provided projecting into the upper portion of said inner annular zone.

6. The apparatus as described in claim 4 further characterized in that a liquid level control means in the upper part of said reservoir connects with and controls a valve in said inlet to said distributing header in said outer zone.

WILLIAM E. I-IULSBERG'.

REFERENCES CITED The following references are of record in the le of this patent:

UNITED STATES PATENTS Number Name Date 1,141,266 Raschig June 1, 1915 1,691,971 Hansard et a1 Nov. 20, 1928 2,207,774 Barthelemy July 16, 1940 

